104740-1640 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047401640 8944778220

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 104740-1640 1047401640

ISUZU 8944778220 8944778220

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Cross reference number

ZEXEL 104740-1640 1047401640

ISUZU 8944778220 8944778220

Zexel num

Bosch num

Firm num

Name

104740-1640
104740-1641

8944778220 ISUZU

INJECTION-PUMP ASSEMBLY
4FC1T *

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113orSAEJ967d

Test oil temperature degC 45 45 50

Nozzle 105000-2010

Bosch type code NP-DN12SD12TT

Nozzle holder 105780-2080

Opening pressure MPa 14.7 14.7 15.19

Opening pressure kgf/cm2 150 150 155

Injection pipe
Inside diameter - outside diameter - length (mm) mm 2-6-840

Transfer pump pressure kPa 20 20 20

Transfer pump pressure kgf/cm2 0.2 0.2 0.2

Direction of rotation (viewed from drive side)
Right R

Injection timing adjustment

Pump speed r/min 750 750 750

Boost pressure kPa 22.85 21.7 24

Boost pressure mmHg 170 160 180

Average injection quantity mm3/st. 45.3 44.8 45.8

Difference in delivery mm3/st. 3.5

Basic *

Remarks
CBS

Injection timing adjustment_02

Pump speed r/min 1250 1250 1250

Boost pressure kPa 64 62.7 65.3

Boost pressure mmHg 480 470 490

Average injection quantity mm3/st. 52.2 51.7 52.7

Difference in delivery mm3/st. 4

Basic *

Remarks
Full

Injection timing adjustment_03

Pump speed r/min 2600 2600 2600

Boost pressure kPa 64 62.7 65.3

Boost pressure mmHg 480 470 490

Average injection quantity mm3/st. 15.6 14.1 17.1

Injection timing adjustment_04

Pump speed r/min 2250 2250 2250

Boost pressure kPa 64 62.7 65.3

Boost pressure mmHg 480 470 490

Average injection quantity mm3/st. 42.35 38.8 45.9

Injection timing adjustment_05

Pump speed r/min 1250 1250 1250

Boost pressure kPa 64 62.7 65.3

Boost pressure mmHg 480 470 490

Average injection quantity mm3/st. 52.2 51.2 53.2

Remarks
Full

Injection timing adjustment_06

Pump speed r/min 750 750 750

Boost pressure kPa 22.85 21.7 24

Boost pressure mmHg 170 160 180

Average injection quantity mm3/st. 45.3 44.3 46.3

Remarks
CBS

Injection timing adjustment_07

Pump speed r/min 600 600 600

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 39.75 36.2 43.3

Injection quantity adjustment

Pump speed r/min 2600 2600 2600

Boost pressure kPa 64 62.7 65.3

Boost pressure mmHg 480 470 490

Average injection quantity mm3/st. 15.6 14.6 16.6

Difference in delivery mm3/st. 3

Basic *

Injection quantity adjustment_02

Pump speed r/min 2800 2800 2800

Boost pressure kPa 64 62.7 65.3

Boost pressure mmHg 480 470 490

Average injection quantity mm3/st. 3.5

Governor adjustment

Pump speed r/min 330 330 330

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 11.3 9.3 13.3

Difference in delivery mm3/st. 2

Basic *

Governor adjustment_02

Pump speed r/min 330 330 330

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 11.3 9.3 13.3

Governor adjustment_03

Pump speed r/min 400 400 400

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 3

Timer adjustment

Pump speed r/min 100 100 100

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 65 55 75

Basic *

Speed control lever angle

Pump speed r/min 330 330 330

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 0 0 0

Remarks
Magnet OFF

0000000901

Pump speed r/min 1250 1250 1250

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Overflow quantity cm3/min 399 270 528

Stop lever angle

Pump speed r/min 1250 1250 1250

Boost pressure kPa 64 62.7 65.3

Boost pressure mmHg 480 470 490

Pressure kPa 470.5 451 490

Pressure kgf/cm2 4.8 4.6 5

Basic *

Stop lever angle_02

Pump speed r/min 600 600 600

Boost pressure kPa 64 62.7 65.3

Boost pressure mmHg 480 470 490

Pressure kPa 313.5 284 343

Pressure kgf/cm2 3.2 2.9 3.5

Stop lever angle_03

Pump speed r/min 1250 1250 1250

Boost pressure kPa 64 62.7 65.3

Boost pressure mmHg 480 470 490

Pressure kPa 470.5 451 490

Pressure kgf/cm2 4.8 4.6 5

Stop lever angle_04

Pump speed r/min 2100 2100 2100

Boost pressure kPa 64 62.7 65.3

Boost pressure mmHg 480 470 490

Pressure kPa 676.5 647 706

Pressure kgf/cm2 6.9 6.6 7.2

0000001101

Pump speed r/min 1250 1250 1250

Boost pressure kPa 64 62.7 65.3

Boost pressure mmHg 480 470 490

Timer stroke mm 2.7 2.5 2.9

Basic *

_02

Pump speed r/min 1250 1250 1250

Boost pressure kPa 64 62.7 65.3

Boost pressure mmHg 480 470 490

Timer stroke mm 2.7 2.4 3

_03

Pump speed r/min 1750 1750 1750

Boost pressure kPa 64 62.7 65.3

Boost pressure mmHg 480 470 490

Timer stroke mm 5.2 4.6 5.8

_04

Pump speed r/min 2100 2100 2100

Boost pressure kPa 64 62.7 65.3

Boost pressure mmHg 480 470 490

Timer stroke mm 6.2 5.8 6.6

0000001201

Max. applied voltage V 8 8 8

Test voltage V 13 12 14

0000001401

Pump speed r/min 1250 1250 1250

Boost pressure kPa 64 62.7 65.3

Boost pressure mmHg 480 470 490

Average injection quantity mm3/st. 34 33.5 34.5

Timer stroke variation dT mm 0.6 0.4 0.8

Basic *

_02

Pump speed r/min 1250 1250 1250

Boost pressure kPa 64 62.7 65.3

Boost pressure mmHg 480 470 490

Average injection quantity mm3/st. 34 33 35

Timer stroke variation dT mm 0.6 0.3 0.9

_03

Pump speed r/min 1250 1250 1250

Boost pressure kPa 64 62.7 65.3

Boost pressure mmHg 480 470 490

Average injection quantity mm3/st. 20 18.5 21.5

Timer stroke variation dT mm 1.2 0.7 1.7

Timing setting

K dimension mm 3.3 3.2 3.4

KF dimension mm 5.8 5.7 5.9

MS dimension mm 1.2 1.1 1.3

BCS stroke mm 4 3.9 4.1

Control lever angle alpha deg. -20.5 -24.5 -16.5

Control lever angle beta deg. 43 38 48

Test data Ex:

0000001801 V-FICD ADJUSTMENT

Adjustment of the V-FICD 1. Adjust the actuator rod to obtain L1. 2. Apply negative pressure P1 {P2} to the actuator and confirm that it moves through its full stroke. (A) actuator shaft (B) Control lever
----------
L=1+1mm P1=-53.3kPa P2=-400mmHg
----------
L=1+1mm

0000001901 POTENTIOMETER ADJUSTMENT

Adjusting method N = pump speed V = output voltage Q = injection quantity P = boost pressure A = adjusting point B = target value Vi = applied voltage
----------

----------
N1=750r/min N2=600r/min V1=2.6V V2=2.0V V3=-V Q1=31.6+-1cm3/1,000st Q2=(23.1)cm3/1,000st Q3=-cm3/1,000st P1=0kPa P2=0mmHg Vi=10V

Information:

Before any service work is done on the fuel system, the outer surface of the injection pump housing must be clean.
Illustrations show fuel injection pump housing and governor removed from engine. Service work can be done with it installed on engine.1. Remove air bleed lines (2). 2. Remove bolts (1), flange (3), the flange assembly and the gaskets.3. Remove the bolts and the cover. 4. Remove bolts (5), solenoid (4) and the gasket.5. Remove two bolts (7) and fuel ratio control (6).6. Remove the shutoff housing from the cover. 7. Remove the bolts, lever (10) and shaft (8).8. Remove the bolts, lever (9) and shaft (11).9. Remove seal (12) from the shutoff housing. Install Shutoff Housing
1. Put 5S1454 Sealing Compound on the outside diameter of the seal and install the seal (1) with tooling (A) in the shutoff housing with the lip toward the outside. The outer face of the seal must be 1.0 mm (.039 in.) below the surface of the housing. Remove the extra sealing compound from the housing and the seal after installation. 2. Put shaft (5) in position in housing (4).3. Install lever (6) and the bolts. 4. Install shaft (2), lever (3) and the bolts. Make an alignment of the notch in shaft (2) with lever (3). 5. Put cover (7) in position on shutoff housing assembly (8) and install the bolts.6. Put fuel ratio control (10) in position and install the bolts. 7. Install the gasket, solenoid (9) and bolts on the cover.8. Put the cover in position and install the bolts.9. Install the gasket, flange assembly, gasket, flange (11) and the bolts.10. Connect air bleed lines (12).